A turbo will help ALOT in reducing the black smoke. I did the banks turbo install myself about seven months after I bought my truck. My truck had 180k miles on it since the last rebuild. How many miles before the rebuild i don't know and neither did the friend i bought the truck from. Most of the time the truck doesn't smoke or blow black smoke unless I try to make it since I installed the manual transmission. The Mileage difference for me is as follows: N/A with E4OD transmission was 12, Turbo with E4OD transmission was 15, Turbo with manual transmission is now 18. I'm in the middle of overhauling my rear axle to 3.55 from 4.10. Also someone started a forum saying he was selling his banks turbo system for $2000. Brand new banks it is $3000. I bought mine brand new. His looks like he planned on doing it and then sold the truck since most if not all of it is still in the plastic bagging. He has the $3000 dollar one. I can tell by the trans command module in the picture for the E4OD. The difference between one for a manual and one for an automatic is the transcommand. The system will fit for the manual transmission too (i should know since i changed mine to a manual) also it includes the new dipstick tube for the auto transmission. One hang up you will hit is that the replacement bolt for your tranny (top drivers side) will be too long. I fixed this by adding washers to space it out, or you might be able to use your stock transmission bolt. Since i have installed the turbo I have put over 30,000 miles on the truck and still running strong, other than my axle issue which is unrelated.
I'm going to copy a post I did on another forum.
I did a minor overhaul on my truck two years ago after i moved 2000 miles. I moved from Bremerton Washington to Muscatine Iowa. During the trip i had over heating issues. Mostly the engine running hot and from time to time bouncing the egt's off 1100 degrees. I was pulling a tow dolly with my 87 ranger 89 f350 fully loaded down with stuff. Total weight was probably 9000 lbs towing. More than once traveling i-90 through washington, idaho, montana, wyoming, and south dakota i had to let off the throttle to keep egts down below 1100 and coolant temps below 235. Anyway, during the overhaul i swapped out the stock radiator for the largest aluminum radiator i could find. I also pulled out all that insulation around the engine bay for less insulation as well as the fact that imho all that does is collect dust dirt and oil. Less than a year ago I pulled the heaviest wight so far for my step dad. I pulled a 1960s small ford tractor weighing about 8000 lbs on my newly bought 3 axle trailer which weighs between 3 and 4000 lbs. On my way to the delivery point there is a steep 7% grade hill for about 1/2 mile. I floored the truck going into the hill and had to downshift about 1/3 the way up. Still floored in 4th gear The truck stayed rock solid at 50 miles per hour. EGT rose and parked at 1000 degrees. Coolant temp rose and parked at 215 degrees. I have the banks wastegate turbo and it parked at 10.5 psi. No intercooler. Since it is not posted on my signature, i have 4.10 gears in the rear. Currently working on my axle to regear to 3.55 gears.
All being said the cooling system does have an effect on temperatures for engine, engine oil, and engine bay can be affected by ripping out that old matting. All that reduction in temperature should reduce the EGTs overall from my experience.
P.S. if i remember right my rpms was about 2300, i dont remember the rpms much as i was paying much more attention to the other gauges. To my surprise i never blew black smoke. My exhaust blew a light white smoke most likely from the cdr valve depressurizing the crank case.
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If you have anymore questions for me feel free to ask.
P.S. If you have never driven these trucks as naturally aspirated then you don't realize how much of a dog they really are. The banks turbo will fix a lot of the underpower and black smoking. I never pulled without the turbo but I can only imagine it being as chris described. Especially at 16 and 11 percent grades. When my truck was N/A would struggle to stay at 65mph going up 6% grades pulling nothing but the truck's weight a total of about 7k lbs with tools ,fuel, and people. 1,000 lb increments has a dramatic effect on a N/A truck. I will add that at first I missed that N/A sound of the diesel chugging. But I have learned to love the turbo sound just as much. Sounds like a 747 jet engine taking off down the runway when she's really working.
